Regular, Routine Maintenance Reminder
This is an Important Reminder from INDUSTRIAL THERMAL SYSTEMS: The efficient and reliable operation of a Benchmark boiler requires regular, routine inspections, replacement of parts, cleaning and maintenance performed by qualified technicians.
7.1 MAINTENANCE SCHEDULE
Benchmark boiler(s) require regular routine maintenance to maintain efficiency and reliability. This summary outlines the critical steps for proper maintenance; the detailed steps required are found in Chapter 7 and Chapter 4 of the respective Benchmark boiler OMM (Operation and Maintenance Manual). Step by step instructions are included in your Boiler(s) respective OMM. Critical maintenance procedures must be performed per the schedule in Table 1.
Table 1: Maintenance Schedule
* Perform only after initial 6 month period after initial startup or an extended shutdown period.
In order to perform the maintenance tasks specified in Table 1, obtain the following maintenance kits for Items requiring replacement every 24 months are included in the 24 month maintenance kits.
Table 2: Benchmark Maintenance Kits and Instruction Documents
7.1 IGNITER-INJECTOR (Part of 6, 12 and 24 Month Maintenance)
All Benchmark Boiler models except the BMK 6000 use igniter-injector (Kit P/N 58023). Inspect per the maintenance schedule and replace it at least every 24 months of operation. Replace sooner if there is evidence of substantial erosion or carbon build-up.
Make sure to use igniter-injectors with black potting material around the ceramic insulator. Do NOT install an older igniter-injector with white potting material.
Failure to follow the igniter-injector maintenance schedule may affect stable ignition and may result in combustion reliability issues and delayed ignition.
7.3 FLAME DETECTOR (Part of 6, 12 and 24 Month Maintenance)
On all Benchmark models except the 6000, the flame detector is located on the burner plate at the top of the unit. Inspect it per the maintenance schedule and replace it at least every 24 months of operation. Replace sooner if there is evidence of erosion, warping or carbon build-up.
Failure to follow the flame detector maintenance schedule may affect stable flame signal and may result in combustion reliability issues.
4.3 COMBUSTION CALIBRATION (Part of 6, 12 and 24 Month Maintenance)
The combustion calibration procedure should be performed every 12 months during scheduled annual maintenance by an INDUSTRIAL THERMAL SYSTEMS trained technician to ensure that the unit continues to operate at optimum efficiency.
7.6 BURNER ASSEMBLY INSPECTION (Part of 24 Month Maintenance)
The burner assembly should be inspected every 24 months to ensure that all components are intact and functioning as designed, without evidence of corrosion, moisture, or other buildup or damage. On all Benchmark models except the 6000, the burner is located at the top of the unit’s heat exchanger, while on the Benchmark 6000 it is located on the front of the heat exchanger assembly.
7.7 CONDENSATE DRAIN TRAP (Part of 6, 12 and 24 Month Maintenance)
Benchmark boilers contain a condensate drain trap located external to the unit, attached to the exhaust manifold drain. trap must be inspected and cleaned every 12 months to ensure that condensate flows normally, does not leak and is not plugged up.
Your system may also have a condensate neutralizer. It requires periodic replacement of its active ingredient.
Read and follow manufacturer’s instructions for replacing neutralizer.
7.8 AIR FILTER CLEANING & REPLACEMENT (Part of 12 and 24 Month Maintenance)
Benchmark 750 through 6000 boilers are equipped with an air filter located at the inlet of the air fuel valve. It should be maintained per the maintenance schedule.
If the air filter is still in good condition after 24 months, you can order a 24 Month Maintenance kit that includes an air filter cleaning kit instead of a new air filter.
Failure to clean or replace the air filter may affect stable combustion, result in less efficient operation, and may result in combustion reliability issues.
7.9 LOW WATER CUTOFF AND TEST (Part of 12 and 24 Month Maintenance)
The low water cutoff (LWCO) capacitor should be tested for electrical shorts every 12 months and replaced and retested every 24 months. The LWCO capacitor integrity test consists of two parts:
- Test for electrical shorting of the LWCO probe capacitor.
- Perform the standard Low Water Cutoff test using the C-More boiler controller. Specific instructions for both parts are included in your boiler’s respective OMM.
7.10 SHUTTING THE BOILER DOWN FOR AN EXTENDED PERIOD OF TIME
If the boiler is to be taken out of service for an extended period of time (one year or more), follow the instructions in your boiler’s respective OMM.
Specific instructions for returning a boiler back to service after a prolonged shutdown are included in your boiler’s respective OMM.